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The Sheybarah Hotel is a hyper luxury resort on Sheybarah Island on the Red Sea archipelago, designed by Killa Design in Dubai. It comprises a series of overwater and inland villas located on the uninhabited Sheybarah Island, 30-minutes by boat from the mainland. The island is home to a highly diverse environment with mangroves, sandy beach, and some of the most beautiful coral reefs in the world.
Each overwater villa is lifted above the water surface, thus reducing the ground foundation impact to a minimum and offers panoramic views to the sea, with sliding doors that open to a deck, a seating area, and an infinity pool with uninterrupted views of the sea and the horizon.
The approach to the façade design has been to minimise visual impact with each villa having polished stainless-steel cladding that reflects the water, the sky, and the reef with the rich sea life below. This material is the key feature of the project and is used in various locations such as the lobby, dining areas, spa, and beach villas.
Having previously successfully collaborated with Killa Design on the Museum of the Future in Dubai, Grankraft was approached during the main contract tender stage to resolve the detailing of the various mirrored stainless steel façades of this project.
The project’s geometry, particularly dealing with the complexity of the shape and the jointing, required every detail to be modeled, analyzed, and optimised in advance of fabrication. Through an extensive sample and mock-up process, Grankraft managed the removal of the hairline joints between the panels, achieving a seamless undistorted mirror stainless steel surface as per the design intent.
By involving Grankraft in early stages of the design, the client was also able to see the mock-up villa pod in person and gain confidence with the immaculate fabrication of the design. Grankraft was approached by the Client with the scheme design package prepared by the consultants and was appointed a Design & Build contract.
Surface temperature = 70 degrees Celsius
0.068 N/mm2 local stress is observed at the bolt location due to extreme temperature gradient. This was achieved because of the in-plane movement permitted at the joint. Due to the swivel loose movement, we felt it may end up with a potential noise issue when the structure breaths in and out during temperature differentials.
3rd proposal, type 3 FX & FY translation locked
For the Sheybarah Hotel, Grankraft has developed a logistic plan in which the capsules will be prefabricated in Grankraft’s facilities in Dubai and will be shipped by sea to the final installation location.
Fabricating the villa pod off-site in our factory increases the quality due to the controlled factory environment. It enables achieving integrated, optimised solutions and coordination of all disciplines, further enhanced through the use of BIM to achieve good design coordination and clash detection between all trades at an early design stage, minimising the potential number of on-site changes as an outcome of the construction sequencing analysis.
Furthermore, the fabrication in our factory not only reduces the cost and time due to higher efficiencies, but also improves health and safety during construction.
1st visual mock-up with type 2 fittings
size of mock-up H = 6m r = 9m
size of mock-up H = 4 r = 5.5 m
A full new production unit has been created in our factory to accommodate the needs of this project and to ensure the maximum quality and accuracy is achieved for the stainless steel shell. The stainless steel panels are first received in our facilities once the production drawings have been coordinated with all trades.
The panels, which at this stage are oversized, are stretched, and bent into shape using a custom-made set of molds created for each specific panel curvature. Once the panels have the required curvature, they are cut into the exact dimensions required. Following this, the edges of the panels are reworked in order to be prepared for the welding operations as part of the pre-assembly. Lastly, the panels are polished to achieve a perfect mirror finish, first using automatic machines and then by hand. To successfully perform these activities, we have developed our own machinery kits which don’t exist on the market.
Once the pre-assembled panels are protected and ready to leave the factory, they are transported to our assembly yard, where the panels are installed to the primary structure using a bespoke mechanical fixation detail which provides thermal and acoustic separation between the façade panels and the structural frame, also allowing for the designed movement depending on the lengths and directions of the panels. After a further control of the geometry, the pre-assembled panels are then welded together, and the final polishing is done.
